Downflow stoker-fed furnace system for bituminous coals



DOWNFLOW STOKER-FED FURNACE SYSTEM FOR BITUMINOUS COALS 9 Sheets-Sheet l Filed May 16, 1949 Sept. 29, 1953 w. J. HATTON ET AL 2,653,555

DOWNFLOW STOKER-FED FURNACE SYSTEM FOR BITUMINOUS GOALS Filed May 16, 1949 9 Sheets-Sheet 2 fige.

INVENTORS Sept. 29, 1953 w. J. HATTON ET AL' DOWNFLOW STOKER-FED FURNACE SYSTEM FOR BITUMINOUS GOALS 9 Sheets-Sheet 3 Filed May 16, 1949 Sept. 29, 1953 w. J. HATTON ET AL 2,653,555

DowNFLow sToKER-FED FURNACE SYSTEM FOR BITUMINoUs coALs Filed May 16, 1949 9 Sheets-Sheet 4 fly. 4.

lNVENTORS SePt- 29, 1953 w. J. HATTON ET AL 2,653,555

DOWNFLOW STOKE-FED FURNACE lSYSTEM FOR BITUMINOUS COALS Filed May 16, 1949 9 Sheets-Sheet 5 Sept- 29, 1953 w. J. HATTON ET ALI` 2,653,555

DOWNFLOW STOKER-FED FURNACE SYSTEM FOR BITUMINOUS GOALS FiledMay 1G, 1949 9 Sheets-Sheet 6 la; F'Jlg. .95 159 169 .94 .92 l lI i .168

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INVENTORS W. J. HATTON ET AL Sept. 29, 1953 DOWNFLOW STOKER-FED FURNACE SYSTEM FOR BITUMINOUS COALS 9 Sheets-Sheet '7 Filed May 16, 1949 NN. E XW ano/P6400 A'Se/man' /Q /Mov/a, awudv @au Sept 29, 1953 w. J. l-lA'rToN ETAL 2,653,555

DWNFLOW STOKER-FED F'URNACE SYSTEM FOR BITUMINOUS COALS` -Filedlay 1S, 1949 9 Sheets-Sheet 8 Figi .9.

INVENTORS Sept. 29, 1953 w, J. HATTON ET Ai. 2,653,555

DowNFLow sToKER-FED FURNACE SYSTEM FOR BITUMINOUS coALs Filed May 16, 1949 9 Sheets-Sheet 9 "l Vang u l s M M b Q D b .7 I 2? U 5 EV- l ---j las I Q i 5 l 22 LTA .L f '-l l i -3 E N INVENTORS Wf//afod /aon and/Pao/)AS/efman Patented Sept. l29, 1953 DOWNFLOW STKOKER-FED FURNACE SYS- TEM FOR BITUMINOUS GOALS Willard J. Hatton and Ralph A. Sherman, Co-

lumbus, Ohio, assignors, by mesne assignments, to Bituminous Coal Research, Inc., Washington, D. C., a corporation of Delaware Application May 16, 1949, Serial No. 93,562

(Cl. 11G- 118) 6 Claims.

This invention relates to an automatic stokerfed furnace system capable of burning a wide range of kinds and sizes of bituminous coals and the like under varying heat demand conditions. More particularly, it relates to a new and practical furnace system for residences and small buildings in which fuel and combustion air are fed downwardly and freely burned Without the material formation of caked masses and clinkersA This new furnace system is also susceptible of use in connection with conventional temperature responsive control circuits.

Unlike many industrial applications having a constant and high heat demand, furnace systems suitable for residences have to be readily responsive to demands varying from territory to territory, from season to season, from daytime to nighttime, and from building heating only to household water heating as well to mention some of the possible variations. Thus, a residential furnace system may have to go from a hold-nre condition to full heat demand and return in a relatively short period of time. In a typical control for such a furnace system, a demand for heat by a master thermostat initiates a full heating cycle during which fuel and combustion air are fed to the furnace for the necessary period required to satisfy that demand. In many cases, this full operation carries on beyond the on period, during which fuel is fed to the furnace. When the call for temperature is satisfied, the furnace system is returned in the usual case to a hold-fire condition. A timer or temperature responsive switch is commonly included in the circuit to periodically feed enough fuel to the furnace system during hold-lire operation to avoid an out-fire. Thus it is that both during heat-demand operation and during hold-fire operation there are on and off periods for the fuel and generally for the combustion air fan also. Any intermediate heat demand in the case of conventional systems may be met by the operation of the furnace under full demand conditions for a shorter period.

Solid fuels such as anthracite coals have long been used in such residential Stoker-fed furnace systems under substantially fully automatic conditions. Such anthracite coals are well suited for this purpose inasmuch as they are regarded as non-caking, non-coking and n'on-clinkering. Inherently, they are relatively smokeless and lend themselves to uniform sizing. Bituminous coals, on the other hand, differ widely in matters of composition, caking, coking and clinkering characteristics. Bituminous coals such as those from the Illinois No. 6, the Pittsburgh seam, the Pocahontas No. 3 bed and Dorothy and Ohio No. 8 beds illustrate the various combinations of these properties which bituminous coals have to varying extents. Inherently, bituminous coals generally present a smoke emission problem and the sizing of such coals is far less precise and uniform than is the case with anthracite fuels. Thus, bituminous coals supplied as Stoker coal, for domestic stokers, may vary between the approximate size limits of from about 11/4" maximum to M3 minimum, a wide size consist in terms of the combustion reactivity of the size gradations present in such a consist.

While bituminous coals with troublesome agglomerating characteristics may be caused to act as a free-burning fuel at rates approximating maximum rates of burning, full advantage could not be taken of this knowledge in conventional residential furnace systems because either the heat output would be beyond the needed requirements or the high temperatures produced would fuse the ash to a degree where it might even become attached to the inside of the furnace, or bothW results would occur. Such rates of burning may be measured in terms of pound weight of fuelburned per square foot of ignition plane area per hour in a furnace system. Further, in conventional furnace systems for bituminous coal, the fuel bed is seldom 'uniform and frequently channels, developments which increase the likelihood of objectionable sooting on the heat transfer surfaces and smoke emission. I-Ience it is that under the fluctuating demands of such smaller furnace systems aggravated by the varying trouble-giving properties of bituminous coals, no`

practical Stoker-fed furnace system has heretofore been devised for operation in homes and small buildings under substantially fully automatic conditions. It is a common experience in those bituminous Stoker-fed furnace systemsin homes today for caked masses and coke trees to form; for clinker to be constantly produced which must be broken up and manually removed;

of its operation. In the sense used herein, equilibrium burning occurs when the fuel bed for a given rate of primary combustion air maintains substantially the same character of combustion and thickness. To accomplish such equilibrium with coalsl having agglomerating properties, such coals must be made to burn in a free-burning, that is, in a non-caking manner. It is made possible principally because this new furnace system produces a higher rate of burning at least during the onv periods lof the control circuit than is possible as a practical matter in any conventionalresidential furnace system employing the underfeed combustion principle. During such higher rates of` burning, the agglomerating properties of the coals used are so reduced that no material. caking occurs to disturb equilibrium and upset the furnace system. All volatile and tarry matters must pass through the fuel bed, that is, the live fuel bed between the plane of ignition and the grate, for effective mixing with combustion air and burning, yielding increased heat release and minimizing or eliminating smoke emission.

Further, a zone of discontinuity is provided between the plane of ignition and the fresh fuel to decrease any agglomerating tendency such as occurs in conventional furnace systems when the fresh unignited fuel remains in continuous contact with the live fuel bed. This zone of discontinuity is-obtained by dropping the relatively cool fresh fuel downwardly on the top of the fuel bed. Combustion air or at least the primary portion thereof in the correlative weight for the weight of fuel being fed is also fed downwardly to the top of the fuel bed which is confined and hence restricts the area of the jagged surface or zone commonly termed the plane of ignition. Any tendency for the rate of ignition measured in Weight of fuel fed per square foot of area at the plane of ignition per hour to exceed the rate of burning in the furnace system may be suppressed by presetting the control circuit to feed a predetermined lesser weight of Ifuel per hour to the furnace system.

In common furnace control circuits, such asl those which are usually preset when installed and seldom if ever changed, this equilibrium cannot be accomplished in anypractical Wayrby slowing the coal feed or by shortening the respective on periods whenthe control is used with conventional Stoker-fed furnaces. The tendency for the rate of ignition to exceed the rate of burning and upset the equilibrium and free-burning of the fuel bed is most likely to occur during hold-fire conditions, although it may also occur under heat-demand conditions when wide size consists are used.

Provision is also made in the new furnace system for agitation and downward-movement of 'the fuel bed and for downward sifting and removal of ashes. Relatively rapid transfer of heat from at least the lower portion of the fuel bed minimizes the formation ofv clinker and such smaller fused ash particles as may occur. are ground suiciently fine to be readily removable automatically from the furnace. Appropriate vertical heat transfer surfaces increase the boiler efficiency and avoid any tendency for fly ash` or fly carbon to be deposited and impair such trans,- fer.

Other objects and advantages of this inven.-`|

tion will be apparent from the following description anddrawings, which are illustrative only, in

which:

Figure 1 is a furnace system assembly embodying this invention;

Figure 2 is an enlarged view in vertical cross section of the furnace shown in Figure 1;

Figure 3 is a View in horizontal cross section taken substantially along line IIIf-III of Figure 2;

Figure 3A is a view in horizontal cross section taken substantially along line IIIA-IIIA of Figure 2;

Figure 4 is a'view in elevation of an embodiment of this invention particularly suitable for use in residences and small buildings;

Figure 5 is-,a plan view of the furnace system shown in Figure 4;

Figure 6-is a vieW in vertical cross section taken alonglineVI-VI of Figure 5, omitting the driving and ash removal mechanism;

Figure 6A is an enlarged fragmentary plan view of the ratchet mechanism for rotating the grate shown in Figure 6;

Figure '7 is a view in cross section taken substantially along line VlI-VII of Figure 6;

Figure- '7A is a view taken along line VIIA-VIIA of Figure 6;

Figure 8 is a view in elevation and partly incross section of the driving mechanism shown-` in Figures 4 and 5;

Figure 9 is a view in vertical cross section taken;

along line IX-IX of Figure 8;

Figure 10 is a partial view in elevation of the coal-feed mechanism shown inFigure 4;

Figure 1l is a partial view in sideelevation of the ash-removal assembly;

Figure 12 is a vertical cross sectional view:

taken substantially along line XII- XII of Figure 11;

Figures '13 to 16 inclusive are elevational andV sectional views of the grate mechanism shown in Figure 6; and

Figure 17 is a diagrammatic representation of a conventional heat-demand control system sultable for use with a furnace system of this, invention such asA those illustrated in this application.

General embodiment The general construction of a furnace system and furnace made in accordance with this invention is illustrated in Figures. 1 to 3A. Fresh fuel.

is fed to the furnace through a conveyor conduit I0 in response to a heat demand or combustion maintenance demand during hold-fire. Conduit I 0 opens through zone I2a into the top of a tubular combustion chamber II so that such fresh fuel drops to the top of the fuel bed therein. Thus, the supply of fresh fuel in the. conveyor.

conduit I0 is never in contact with the fuel in the.

fuel bed because of the spatial discontinuity de,- liberately providedv by zone I2a. The. combustion air is fed into combustion chamber II through a port I2 to the fuel bed in the same direction as the fresh fuel. In this embodiment, a restricted portion I3 of combustion chamber IIV is fashioned in frusto-conical shape, a matter the significance of which is more fully treated in United States patentV application Serial No. 98,484, filed June 11, 19.49, in the name of Willard J. Hatton,

and Henning M- Carlson. The confined portion of combustion chamber I I including portion I3 is lined with a refractory 34. to assist in main taining ignition during hold-fire periods when minimum heat output to maintain combustion is all that is needed.

The furnace illustratedv in Figures 2 toj3A.may

be employed in a general assembly as shown in Figure 1. In this assembly a fuel bin 22 has a hopper 23 therein to which access is provided by a cover 24. Hopper 23 has a lower converging portion 25 surrounding a feed screw 26 which is universally coupled to an inclined extension 21 thereof. Extension 21 is enclosed within a conduit 28 joined at its upper end to the outer end of conduit Ill. Conduit I in turn empties into a turret 29 closed by a cover 30 directly above combustion chamber I I. Port I2 in turret 29 is connected by a duct (not shown) to duct 3I leading to an air blower 32. Feed screw 26 and blower 32 are both turned by an electric motor 33. A suitable clutch is interposed between motor 33 and feed screw 26.

The lower end of combustion chamber II broadens out around a conical grate I4. Grate I4 is supported in fixed, eccentric position on a rotating base I5. Ash passes between base I and the lower portion 35 of an annular boiler or water jacket I1 into an ash pit I6 where it is removed.

Jacket I1 surrounds combustion chamber II, the grate I4, base I5 and ash pit I6. A plurality of vertical annularly disposed flue tubes I8 pass through jacket I'I between the top thereof and the offset portion thereof at the top of the broadened part of combustion chamber II. lIn this way, gaseous combustion products, which include any vapors and entrained material therein, pass through the live fuel bed substantially beginning at the plane of ignition in portion I3, around said projecting part of jacket I1 and upwardly through tubes I8 and out through a flue collar I9 and a stack51, resulting in high rates of heat transfer to the watery or other suitable heat absorbing fluid, in jacket I 1, without deposition of soot or ily ash on the internal surfaces of the tubes. Water enters jacket I1 through a line 36 and after circulating through the jacket and absorbing heat leaves jacket I1 through a line 31 connected to a hot-water radiator or other type of heating system for the household or small building in which the furnace is installed. A second electric motor (not shown) forces water at a predetermined rate through said jacket.

The lower end of jacket I1 absorbs heat directly from the lower` portion of the fuel bed, thereby aiding in the maintenance of temperatures at least in the lower portion of the fuel bed which discourage any material formation of clinker by the melting or fusion of ash. Additional cooling in the lower portion of combustion chamber I I may be obtained if desired by the provision of some supplemental combustion air through a line 2l and ash pit I6. Such supplemental combustion air will also mix up and burn any combustible which ymight otherwise tend to be present in the ash and in the gaseous combustion products. Normally, such supplemental combustion air would not be in excess of one-quarter by weight of the combustion air supplied to the furnace through port I2.

A metal liner 38 surrounds the lower portion of combustion chamber II in contact with lower wall 35. The inside of liner 38 is in vertical registry with wall 35 above it so that fly ash may have substantially no non-vertical surface or land on which to deposit in the furnace. A series of vertical grooves 39 are disposed around the inside of liner 38 and cooperate with a plurality of grooves 4I in grate I4 and with its lower vertical edge 40 to break up such small clinker particles as may form. ASufficient clearance is left between the edge of base l5 and the interiore! liner 38 so that only readily removable ash falls into ash pit I6. A sweep 42 is adjustably affixed to the underside of base I5 and pushes ash out of ash pit I6 through an opening 43 leading into an ash removal duct 44. A bottom plate 45 closes of shaft 46 and is engaged by a worm gear 5Iy at the end of a shaft 52 or by a suitable ratchet drive. Shaft 52 is also provided with an ash removal feed screw 53 in a conduit 54. Duct 44 opens into conduit 54 so that the turning of shaft 52 either by motor 33 through appropriate connections (not shown) or otherwise, not only rotates grate I4 but also causes the ash to feed into an ash receiver 55 having a cover 56.

At the commencement of a heating season or following an out-fire, if an automatic igniter is not employed, the furnace illustrated in Figure 2 may be manually ignited by removing cover 30 and filling combustion chamber I I to the appropriate level in portion I3 with coke or charcoal and sufficient kindling to be readily ignited by a. match or other lighter when air is fed to the bed by starting motor 33 with the clutch to feed screw 28 disengaged. After the kindling and starting fuel bed becomes ignited, the clutch is engaged and regular operation of the furnace system commences. Thereafter, this furnace system under the control of its preset conventional control circuit and a preset damper 58 in duct 3| will operate in equilibrium during heat demand and hold-fire periods. In this operation combustion air normally in excess of that required for theoretical perfect combustion for the weight of fuel fed is supplied through port I2 at ambient temperature or preheated. If preheated, as is well understood, the reactivity of the operation is increased and the presetting of the control circuit will make due allowance therefor. All fresh coal fed to this new system is relatively rapidly ignited and burned at a high rate in relation to any previously known furnace systems for such use. Such high rate burning continues at least until all troublesome caking tendencies are suppressed. Thereafter, as in the case of an off period during hold-fire operation, the chimney effect induced by the draft through stack 51 will normally provide sufficient air for the maintenance of combustion. Some additional combustion air, if desired, may be supplied during lsuch off periods. The plane of ignition of the fuel bed will remain in the confined portion of combustion chamber I I at all times in order to realize the full advantages of this invention. If that confined portion has vertical sides throughout the length thereof, a greater excess of combustion air will usually be required for optimum operation.

Further embodiment In such embodiment, a cylindrical casing 10 isr mounted on legs 1I. A substantially annular 7. Outif jacket' 12.t s,rin; casing 10; and contains-j menor otherihig-h heat. transfer fluid. Jacket 12;,has; anlinnermetal vertical wall 13; somewhat accentrically placed `in, casing 10 as; illustrated, in, Figure` '7. Two; vertical cyclones 10 pass thrughthe interior` of jacket 12 from topto adjacent the position in which wall 13. is farthest from casingv10l- Cyclones14 are. provided with casings 15, which are,` sealedandharveno communication' with 'the .interior `of jacket,` 12, NLW'ith respective tangential inlctopenings 16 oppositely disposed relativeone another. Outwardlyexpandlng; passagesy 11 connect each: openingv 1 with that, portion of a combustion chamber 10..,whichris immediately adjacent the upper part.' ofwall-13.. An innerjacket 19A of an irregulax-annular shape having an outer wall 80and an inner wall8| is positioned concentrioto Wall 13 in the; top of casingv 10 where it is supported by a caveLcSZbolted to a topplate 83 forming the top otcasing 10 and jacket 12. Jacket 19 is interconnectedtojacket'12 by awater line 84. Water enters-jacket. 12 adjacent the bottom thereof througha line vBti-fand leaves jacket'19 through anoutletl 8E.

WallV 80. isspaced from wall 1-3, toI enable gaseous combustionproducts to transfer heat to the water in jackets 12 Vand 19 respectively through metal'walls 13` and 80. Inner wall 8| outwardly flares Aat the top- 81 thereof. is tubular in character atan intermediate portion 88 and assumes a tubular -frusto-conical shape at a lower portionx09 thereof'. Flared portion 81 is closed by a domed'cover Sil-having a centrally rising duct therein which is capped byV a double outlet memberfSZ, one of which outlets is sealed by a plus ,932whioh is. removable'fornihspection and, if` required,- manual ignitionpurposes. The other outlet of member 92 v'is connected to a coal feed screw conduit 94. An outlet 95 in cover 80 is connected to a .primary combustion air inlet duct 96.v A smaller duct 91 branches off from duct 98 and is coupled to a vertical-duct 98 connected to a collar 99 having a hollow center therethrough for the passage of supplementary combustion air to the furnace. An automaticl ig-niter having a spark plugv |0|vand an igniting .gas inletY |02 may be vprovided as more fully set forth in United States patent application Serial No.` 114,772, ledseptember 9, 1949, in theV name of Willard J. Hatton. Such an automatic igniterfacilitates the kindling of a fuel bed in,k the furnace in the-event of an accidental out-fire andfurther, reignites a fuel bed in the furnace following the. time when furnace controls are so set that combustion is purposely lost at times of.y no heat. demand. In residences and small' buildings during` Very mild weather especiallyv evenvthe small heat release of hold-fire conditions. may occasion an uncomfortable temperature within the home or building.

A combustion chamber |03 normally extends between a plane of ignition in the confined upper tubular portion thereof, generally represented by Wallportions 88 and 89, and the top of a rotating baseplate 04, at the bottom of the broadened portion Aof combustion chamber |03. mountedincoaxial relation to jacketA 19. A conical grate |05 is rigidly affixed to base |04 eccentrically of the center thereof so that a vertical lower circular edge |06 at the baseofgrate |05 is. internally tangent to-the periphery of plate, |04.AA Recesses |01 are equally spaced around the4 conical surface of grate |05 and extend from the topof edge |06 a substantial distance toward the Base. |04 isY apex of thegrate. Recesses |01; usually are cast or milled and have flat bottoms` which are so angled relative thev conical surface of grate |05 that a shoulder |08gis produced opposed to the direction of rotation of base` |04. A supplementary combustion air inlet port |09 extends through each shoulder |08 along at least a part of the length.. thereof. These recesses are adapted to promote the descent and eventual crushing of any small clinker particleswhich may be formed duringoperation. A hub ||0 is keyed to a hollow shaft in turn keyed to and turned by a ratchet wheel` ||.2j. The lowerhorizontal bearing surface of hub |,|0 ,supports the'V fuel bedA and thegrate mechanism by being mounted in thrust engagement against a bearing boss ||3 integral with a closure kplate ||.4 forming the bottom of an ash pit |.|5 beneath base-|04 v A bottom plate ||B constitutes a fixed ,bottom for casing 10 including wall 13 to. which it is welded or otherwise sealed to avoid any leakage from outer boiler portion 12. Plate; ||6 also hasopenings sealed around the lower reduced ends l I1 of the respective cyclones 14 where they pass through. Plate ||5 further has anopenihg therein to accommodate the insertion and removal of the grate mechanism and a. crushing. wall liner |.|8. This opening is ringed bya depending flange ||9 snugly fitting around the periphery of closure plate |,4 which is tapped for engagement by bolts passing through flange i9. Crushing wall I8. nts snugly against a lower annular portion of wall 13 which is set back so that, the interior of liner I8 and of wall 13 present a substantially unbroken verticalv surface. Vertical grooves |204 are disposed around the inside. of liner ||8 and cooperate with recesses |01, the periphery of plate, |04 and the tangential portion of edge |06 in reducing any small clinkers that may tend to, beformed so that the fragments thereof will passthrough the clearance space between base |04 and liner ||8 and fall into ash pit l5'.v An ash removal duct |2 |l is connected to ash pit ||5 `through closure plate |4 and the contents of ash pit ||5 are fed into duct `|2| by means of a depending sweep |22 adjustably connected to the bottom of base |04 so the clearance thereof above the floor of ash pit ||5 may be varied as desired.

A grate pan 23 underlies closure plate |4 andv surrounds lower hub portion |24 of plate ||4 which lower hub portion guides shaft Pan |23 is fastened to. bottom IIB by stud bolts |25. Bearings |26 `are interposed between the hub of ratchet wheel ||2 and stationary collar 99 and the non-'rotating hub |24. If desired, roller bearings may be interposed between hub |3 and base |04. The lower end of hollow shaft forms a sliding t'with the upper end of duct 98 adjacent collar 99 in which conventional gasket sealing means are provided to prevent the escape of air. In addition, anyl leakage of air from the furnace system yof -this invention is avoided as much as possible by making all joints tight.

Driving mechanism for further embodiment AA rigid base |30 is positioned adjacent the bottom of the furnace and has mounted thereon an electric motor |30. having4 a shaft, |32 coupled to a shaft. |33 .of acentrifugal water pump |34 which is also mounted on base |30.` Water to be heatedis supplied to pumpl |34 through a line |35 and is delivered througha line |36 to, inlet 85,. A second motor |3| has its shaft |31 'coupled to a'power input shaft |38 of a gear train en closed withina gear box |39.; Shaft |38 extends through gear box |39 and is coupled to a shaft |40 which operates a rotary fan blower |4|, the outlet of which is connected to duct 96 to supply combustion air to the furnace system. A worm gear |42 on shaft |38 rotates a worm wheel |43 which in turn rotates a double-ended sprocket shaft |44. A sprocket |45 keyed to one end of shaft |44 operates the ash removal screw. A sprocket |46 at the other end of shaft |44 operates a coal feed screw. A plate |41 is bolted to the end of shaft |44 adjacent sprocket |45 and has a stud bolt |48 serving as an eccentric pivot for a connecting bar |49. Connecting bar |49 is in turn pivoted to a double ratchet arm |58 spanning both sides of ratchet wheel ||2. Ratchet arm |50 is integral with bearings |29 which are a part thereof. Between the sides of arm |50 a ratcheting pawl is pivotally mounted for respective engagement with teeth |52 around the periphery of ratchet wheel ||2. A spring |53 urges paw] |5| into engagement with teeth |52. Hence, rotation of shaft |44 causes an intermittent angular advancement of wheel |12 and corresponding movement of grate |05. Various conventional means may be used, which are not illustrated, for varying the speed of ratchet wheel |2. In general, the speed of the ratchet wheel i2 may be set somewhat lower for expected fuels having lower ash contents and, further. such speed should not be so high as to increase the amount of combustible normally to be found in the ash.

A horizontal shaft |54 is mounted in a bracket |55 on a Ibase plate |55` above base |30. A sprocket |51 is keyed to the outer end of shaft |54 and is turned by sprocket |46 through a chain |58. The inner end of shaft |54 turns an inclined shaft |59 through a universal coupling |50. Shaft |59 is journaled at its upper end in a bearing |64 integral with cap piece 92. A bevel gear |65 is keyed in fixed position to shaft |59.

Within conduit 94 a coal feed screw |68 is Dositioned, the shaft of which is keyed to a bevel gear |69 having a hub which takes up the thrust of the screw against a bearing portion on cap 92. Bevel gear |69 is in engagement `with gear |55 and hence when motor 3| is turned on by the control circuit, coal is fed into the furnace. The other end of conduit 94 leads into a coal hopper or bin of a conventional type lfor Supplying coal to stoker screws.

Ash, removal mechanism for further embodiment Duct |2| is joined to an inlet |10 integral with a closed ash removal screw conduit |1|. A shaft |12 in conduit |1| has screws of opposite hands extending outwardly from each side of the center thereof. A sprocket |13 is keyed to shaft |12 and turns shaft |12 by means of a chain |14 which is also in engagement with sprocket |45. Inlet is adjacent the midpoint of conduit |1| which midpoint receives ashes forced toward it by both screws causing the ashes to enter a discharge chute surrounding conduit |1|. The outer end of discharge chute |15 opens into an ash bin |16 having a removable cover |11 facilitating the emptying of the ashes in bin |16. Duets |18 respectively lead from reduced portions ||1 of the respective cyclones 14 to inlets into conduit |1| adjacent thereto. In this way, ashes from ash pit ||5 and ash removed from the combustion gases by cyclones 14 are taken by the ash removal screws and emptied into receiver |16.

Before passing through cyclones 14, the gaseous combustion products transfer heat to the re- 10 spective water jackets particularly through walls 13 and 80. The cooled gaseous combustion products rise in cyclones 14 and pass out through a stack |19.

Conventional control suitable for new furnace system A number of the conventional heat demand control systems used in homes and small buildings may be applied to the furnace system of this invention to effect the automatic operation thereof. By way of illustration only, one such control is illustrated in Figure 1'7 herein. In this figure electric power is obtained across lines L| and L-Z to which the control circuit is connected through a switch |80. A low-limit mercury switch |8| guarantees a predetermined minimum water temperature; a normally open mercury stack switch |82 guarantees proper ignition conditions; a normally closed high-smit mercury switch |83 prevents excessive temperatures in the furnace system; and an over-run control mercury switch |84 prevents overheating of the boiler water by circulating cooler water when the temperature of the heated water tends to exceed a predetermined maximum. A motor |86, which may be similar to motor |30', controls the circulation of Water in the furnace system. A motor |81, which may be similar to motor |3| or motor 33, controls the coal .feed and the combustion air blower. Upon a call for increased temperature by a room thermostat |85, heat demand contacts |88 and |89 and a second pair of contacts |90 and |9| in thermostat will close. The flexing of contact |0| is such that it closes with contact |90 before pair ISB-|89 closes and, conversely, pair |88|89 opens before pair |90-49|.

This call initiates an on period for motors |86 and |81 through a relay |92, the energization of which respectively closes contact bars |93 and |94. As soon as the temperature call begins to be met, contacts |88-|89 open but a holding circuit remains closed through a secondary winding |95 of a transformer |96 andcontacts |90- |9|. When the temperature demand is met, thermostat |85 breaks contacts |90-ISI opening contact bars |98 and |94 and stopping motor |186. Motor |81 is stopped whenever switch |8| opens upon reaching a predetermined increase in the temperature of the water in the system required to satisfy the temperature call. Switch |8| will remain open until the Water temperature in the boiler falls below the preset minimum. So lons as both switch |8| and stack switch |82 are open Y motor |81 and at least the fuel feed for the system will be off, if there is no call for heat by room thermostat |85.

Illustrative example A representative furnace system made in accordance with this invention might require a heat release of about 180,000 B. t. u. per hour for an average-size house of six rooms in the northeastern part of the United States using hot water radiation or Warm water heating. On the basis of an overall furnace efficiency of '70% and a maximum operating factor of 70%, the heat output per hour will approximate 90,000 B. t. u. Setting such a maximum operating factor would permit the furnace system to be overloaded whenever necessary for short periods of time. If a bituminous coal having a heating value of about 13,360 B. t. u. per pound is used, such an output would require about 131/2 pounds of fuel feed to the furnace of the system in each hour. In genaeo'asss not exceed about 20 pounds of fuel feed each hour to satisfy the expected maximumheat demand and may be considerably less. Under hold-fire conditions, in the above-described` operation, it l maybe assumed, for example, that between about 0.75 and 1.75 lbs. of a bituminous coal having the aforesaid heating value might be required to maintain ignition and prevent any out-fire, with such coal having a minimum heat output of about 11,000 B. t. u. per hour.

The-boiler of such a furnace may have a water capacity of about 20 to 25 gallons. The combustion chamber of such a furnace might vary between about 4 and 8" in diameter in the confined portion thereof and be of sufficient height to accommodate a live fuel bed which might vary from a depth of about '7 to about l5", measured from the base plate to the plane of ignition in the confined portion of the combustion chamber. In a combustion chamber of such small size, the actual rate of burning during the on fuel feed feed below themaximum burning rate potentialf of atleast the more reactive particles therein will yield` free burningaction by such suppressionof the ignition rate for hold-fire operation, wide size consists, and unusually troublesome agglomerat ing coals.

The downflow combustion air tothe furnace y usually has the same on periods as the fuel and may vary from the theoretical air value for perfect combustion to possibly about twiceithe theoretical value. In general,r` a substantial excess air setting will be required particularly for hold-fire operation. If a timer is included in the control circuit, maintenance of combustion during hold-fire periods may possibly bel provided for by having an on fuel feed period 'occur possibly about four times inI each hour. When supplemental combustion air is fed to the furnace system, it normally will range between about and 25% of the total combustion air. On the other hand, the correlation of weight of combustion air to the weight of fuel Vfed is selected so as not to causeany blow-out and any supplemental combustion air must'notbeadded in such magnitude' as to aggravate any fly ash problem. Sufficient flexibility existsv in the' furnace system of this invention for readily understood adaptation to the variables which will be encountered in particular applications.

It will thus be seen that in this invention a small furnace is provided to whichA bituminous coal and air in correlative amounts are periodicallyior continuously fed as demand requires tov the top of a live fuel bed, the upper part of which is confined in a restricted zone within'the furnace. A zone of discontinuity is providedV substantially at the plane of ignition so that the coal remains relatively cooluntil itis actually subjected to kindling conditions at the time it is'so fed. Under the high rate of burning that ensues at least during the on periods of heat demand and hold-fire, all volatile and tarry matter released passes through the fuel bed whence the heat release potentiality thereof is recoveredand smoke emission which might otherwise be caused thereby is prevented. The agglomerating properties of such volatile and tarry' matter vare sup-` pressed or destroyed'during such active burning and remaining agglomerating tendency, if any, is nulliiied by ignition suppression inherentin the predetermined presetting of the control cir"-`V cuit. The particles in the fuel bed gravitate downwardly into the unconfined lower portion of the combustion chamber where gaseous combustion products escape through the upper surface of said bed. Ash also gravitates downwardly" through the fuel bed and out of the combustion chamber before any material clinkering thereof can take place. nism, this continual sifting out of ash is pro'- moted and the formation of troublesome'agglomerations of fuel masses and of ash is suppressed. The proximity of liquid-cooled boiler' walls help to prevent potential clinker formation. The gas-to-liquid heat transfer surfaces are also proximate and vertical to maintain high lheat transfer rates and avoid deposition of soot and fly ash.

Although certain practices of this invention have been illustrated and described in the foregoing specication, it is to be understood that modifications may be made therein without departing from the spirit of the invention or the.

scope of the appended claims.

We claim:

1. In a heating furnace system for burning solid organic fuels including agglomerative bituminous coals, the steps comprising, maintaining a live fuel bed in a combustion zone, laterally confining the upper part of said live fuel bed ina smaller area than the area of the base of said.

fuel bed, maintaining fresh fuel separated from any contact with said live fuel bed, feeding-that quantity of fresh fuel which can come into sub-.

stantially direct contact with the confined top ,ofi said live fuel bed not to exceed a thin layer of said fresh fuel, and feeding primary combustion air downwardly past said fresh fuel so fed and into said live fuel bed substantially over the entire area of said confined top, whereby such solid organic fuels which tend to agglomerate will beprevented from caking in the course of being burned in said furnace system.

2. In a heating furnace system for-burning solid organic fuels including agglomerative bi-` tuminous coals, the steps comprising, maintaining an incandescent fuel bed in a combustionY zone, laterally confining the upper part of saidv incandescent-fuel bed in a smaller area than the area of the base of said incandescent fuel bed. maintaining fresh fuel separated from any contact-with said incandescent fuel bed, dropping.

through Yspace that quantity of fresh fuel which cari come yinto lsubstantially direct contact with.` the confined top of said incandescent fuel bed not tovexceed a thin layer of said fresh fuel, andv substantially simultaneously feeding primary combustion air through said space over said fresh including agglomerative bituminous coals; thel steps comprising, maintaining a live fuel bed in a combustion zone, said live fuel bed having its plane of ignition substantilaly coincident with the surface of the top of said live fuel bed, laterally confining said top of said live fuel bed in an area smaller than the area of the lower part' of" By agitating the grate mechasaid live fuel bed, maintaining fresh fuel separated from any contact with said live fuel bed, passing primary air for combustion downwardly into said live fuel bed through said confined top thereof and substantially over said entire surface of said confined top, feeding a thin layer of fresh fuel to said surface of said confined top of said live fuel bed for rapid kindling of said thin layer of fresh fuel, and repeating said feeding of fresh fuel in correspondence with the heat demand requirements of said system.

4. In a heating furnace system for bituminous coals or the like, apparatus comprising, in combination, a vertical tubular jacket having upper and lower inner Walls, the distance between the sides of said upper inner wall being less than the distance between the sides of said lower inner wall, the space between the sides of said lower inner wall and between the sides of the lower part of said upper inner wall defining a combustion chamber for a live fuel bed having its top confined by said lower part of said upper inner wall, said combustion chamber having a passage communicating with the portion thereof within said lower inner wall for the removal of gaseous products from said live fuel bed, a conveyor connected to said jacket to feed fresh fuel in a quantity constituting a thin layer thereof in each such feeding from a fresh fuel supply outside said inner walls, said feeding being between the sides of said upper inner wall above said confined top of said live fuel bed, an inlet duct connected to said jacket to pass primary combustion air downwardly between the sides of said upper inner wall above said confined top of said live fuel bed for distribution over substantially the entire area of said confined top, and a control for repeating said feeding in accordance with the heat demand requirements of said heating furnace system.

5. In a heating furnace system for bituminous coals or the like, apparatus comprising, in combination, a vertical tubular outer jacket member having the bottom of a combustion chamber between the sides of a lower part of the inner wall of said outer jacket member, a vertical tubular inner jacket member extending downwardly within the upper part of said outer jacket member, said inner jacket member being in coaxial relation to said outer jacket member and having an inner wall defining the top of said combustion chamber between the sides of the lower part of said last mentioned inner wall, the top of said combustion chamber being adapted to laterally conne the top of a live fuel bed in the top of said combustion chamber and having its plane of ignition substantially at the surface of said confined top off said live fuel bed, a passage between the outside of said inner jacket member and said inner wall of said outer jacket member for gaseous products from said live fuel bed, a conveyor connected to said inner jacket member to feed fresh fuel in a quantity providing not to exceed a thin layer thereof from a. fresh fuel supply separated from said jacket members, said feeding being between the sides of said inner wall of said inner jacket member above the surface of said confined top of said live fuel bed, -an inlet duct connected to said inner jacket member to pass primary combustion air downwardly between the sides of said inner Wall of said inner jacket member above said surface of said confined top of said live fuel bed for distribution over substantially the entire area of said surface, and a control for repeating said feeding in accordance with the heat demand requirements of said heating furnace system.

6. In a heating furnace system for bituminous coals or the like, apparatus comprising, in combination, a vertical tubular outer jacket member having the bottom of a combustion chamber between the sides of a lower part of the inner wall of said outer jacket member, a. vertical tubular inner jacket member extending downwardly Within the upper part of said outer jacket member, said inner jacket member being in coaxial relation to said outer jacket member and having an inner wall defining the top of said combustion chamber between the sides of the lower part of said last mentioned inner wall, the top of said combustion chamber being adapted to laterally confine the top of a live fuel bed in said combustion chamber and having its plane of ignition substantially at the surface of said confined top of said live fuel bed, a horizontally movable grate extending across the bottom of said combustion chamber, an upwardly and outwardly extending passage between the outside of said inner jacket member and said inner wall of said outer jacket member for gaseous products from said live fuel bed, an ash collector connected to said combustion chamber for receiving ashes from said combustion chamber, a conveyor connected to said inner jacket member to feed fresh fuel in a quantity providing not to exceed a. thin layer thereof from a 'fresh fuel supply outside of said jacket members, said feeding being between the sides of said inner wall of said inner jacket member above the surface of said confined top of said live fuel bed, a fan to feed primary combustion air downwardly between the sides of said inner wall of said inner jacket member above said surface of said confined top of said live fuel bed for distribution over substantially the entire area of said surface, and a control for repeating said feeding in accordance with the heat demand requirements of said heating furnace system.

WILLARD J. HATTON. RALPH A. SHERMAN.

References Cited in the le of this patent UNITED STATES PATENTS Number Name Date 76,010 Watts Mar. 24, 1868 373,835 Lindemuth Nov. 29, 1887 481,216 Watson Aug. 23, 1892 595,339 Rahner Dec. 14, 1897 619,709 Bair Feb. 21, 1899 902,714 Cope Nov. 3, 1908 1,416,995 Stroud May 23, 1922 1,548,292 Wedge Aug. 4, 1925 1,624,908 Bowman Apr. 19, 1927 1,848,878 Hagstrum Mar. 8, 1932 2,014,868 Steele et al. Sept. 17. 1935 2,180,196 Corbett Nov. 14, 1939 FOREIGN PATENTS Number Country Date 433,085 Germany Sept. 15, 1926 

